Identifying Thermal Processing Torch Components

ABSTRACT

In some aspects, a method for identifying a consumable of a thermal processing torch comprising can include directing a gas flow through a flow-restriction element associated with the consumable disposed within the thermal processing torch; determining a first pressure of the gas flow at a location upstream relative to the flow-restriction element; determining a second pressure of the gas flow at a location downstream from the flow-restriction element; determining a flow rate of the gas flow passing through the flow-restriction element; and using the first pressure, the second pressure, and the flow rate to identify the consumable.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Ser. No. 13/838,919,filed Mar. 15, 2013 and titled “Systems, Methods, and Devices forTransmitting Information to Thermal Processing Systems,” which is acontinuation-in-part of U.S. Ser. No. 13/560,059, filed Jul. 27, 2012and titled “Optimization and Control of Material Processing Using aThermal Processing Torch,” which is a continuation-in-part of U.S. Ser.No. 13/439,259, filed Apr. 4, 2012 and titled “Optimization and Controlof Material Processing Using a Thermal Processing Torch.” Thisapplication is also a continuation-in-part of U.S. Ser. No. 13/560,059,filed Jul. 27, 2012 and titled “Optimization and Control of MaterialProcessing Using a Thermal Processing Torch,” which is acontinuation-in-part of U.S. Ser. No. 13/439,259, filed Apr. 4, 2012 andtitled “Optimization and Control of Material Processing Using a ThermalProcessing Torch.” The contents of all of these applications are herebyincorporated herein by reference in their entirety.

TECHNICAL FIELD

This disclosure relates generally to thermal processing torches and moreparticularly to identifying thermal processing torch components.

BACKGROUND

Thermal processing torches, such as plasma arc torches, are widely usedin the heating, cutting, gouging and marking of materials. A plasma arctorch generally includes an electrode, a nozzle having a central exitorifice mounted within a torch body, electrical connections, passagesfor cooling, and passages for arc control fluids (e.g., plasma gas).Optionally, a swirl ring is employed to control fluid flow patterns inthe plasma chamber formed between the electrode and the nozzle. In sometorches, a retaining cap can be used to maintain the nozzle and/or swirlring in the plasma arc torch. In operation, the torch produces a plasmaarc, which is a constricted jet of an ionized gas with high temperatureand sufficient momentum to assist with removal of molten metal.

Typically, a plasma arc torch includes multiple consumables. Eachconsumable can be selected to achieve optimal performance (e.g., anoptimal current level, maximum lifespan, etc.) in view of specificprocessing constraints, such as the type of material being cut and/orthe cut shape desired. Installing incorrect consumables into a torch canresult in poor cut quality and decreased cut speed. In addition,incorrect consumables can reduce consumable life and lead to prematureconsumable failure. Even when correct consumables are installed in atorch, it can be difficult for an operator to manually configure andoptimize torch operating parameters corresponding to the selectedconsumable set. Moreover, it can be difficult for a torch componentmanufacturer to guarantee performance if aftermarket consumables areused in a torch system.

SUMMARY

Thus, systems and methods are needed to detect consumables installed ina plasma arc torch (e.g., detect incompatible consumables installed in aplasma arc torch). Specifically, systems and methods can be used toefficiently convey information among various components of a torchsystem to facilitate operation control and optimization.

In some aspects, a method for identifying a consumable of a thermalprocessing torch can include directing a gas flow through aflow-restriction element associated with the consumable disposed withinthe thermal processing torch; determining a first pressure of the gasflow at a location upstream relative to the flow-restriction element;determining a second pressure of the gas flow at a location downstreamfrom the flow-restriction element; determining a flow rate of the gasflow passing through the flow-restriction element; and using the firstpressure, the second pressure, and the flow rate to identify theconsumable.

Embodiments can include one or more of the following features.

In some embodiments, determining the first pressure can include settingthe gas flow to a known pressure and determining the flow rate caninclude measuring the flow rate. Determining the flow rate can includesetting the gas flow rate to a known value; and determining the firstpressure can include measuring the pressure of the gas flow. Determininga second pressure of the gas flow can include establishing the pressureas atmospheric pressure (e.g., 0 psig). The flow-restriction element canbe an orifice associated with the consumable. In some cases, the methodcan also include using a flow coefficient equation to determine thedimension of the orifice based the first pressure, the second pressure,and the flow rate. In some examples, the dimension of the orifice can becorrelated to the consumable or a type of the consumable for identifyingthe consumable. In some cases, the flow-restriction element can be anexit orifice of a nozzle. The flow-restriction element can alternativelyor additionally include a vent hole of a nozzle or a swirl ring. In somecases, different flow-restriction elements are selected for differenttypes of consumables. In some cases, the flow-restriction element caninclude absence of a vent hole.

In some aspects, a method for identifying a consumable of a thermalprocessing torch (e.g., a torch that includes a plasma chamber definedby an electrode and a nozzle) can include directing an inlet flow of agas through a gas supply line to the plasma chamber; manipulating atleast one of: a) the inlet flow of the gas to the plasma chamber using aregulator coupled to the gas supply line until a criterion is reached orb) a vent valve coupled to a vent line connected to the plasma chamberto control an outlet flow of the gas from the plasma chamber;determining a first value of at least one operating parameter of thetorch associated with one of the inlet flow or the outlet flow of thegas; and identifying the consumable based on the first value of the atleast one operating parameter.

Embodiments can include one or more of the following features.

In some embodiments, manipulating the vent valve to control the outletflow of the gas from the plasma chamber can include limiting the outletflow of the gas from the plasma chamber prior to the criterion beingreached. The method can also include manipulating the vent valve topermit the outlet flow of the gas from the plasma chamber through thevent line after the criterion is reached; determining a second value ofthe at least one operating parameter of the torch; and using the firstvalue and the second value of the at least one operating parameter toidentify the consumable. In some examples, the at least one operatingparameter can include one of a supply pressure of the inlet flow, a flowrate of the inlet flow, an off-valve pressure of the inlet flow, or aflow rate of the outlet flow. In some cases, the supply pressure of theinlet flow or the flow rate of the inlet flow can be measured between agas supply valve and the regulator coupled to the gas supply line, theregulator being positioned downstream from the gas supply valve. In somecases, the off-valve pressure of the inlet flow can be measured by apressure transducer positioned downstream from the regulator on the gassupply line. The flow rate of the outlet flow can be measured at thevent line. The method can also include using a lookup table to identifythe consumable based on the first value, where the lookup tablecorrelates one or more consumables with respective values of one or moreoperating parameters. In some examples, the criterion can include athreshold pressure value of about 4.0 pound per square inch (psig) inthe plasma chamber. The consumable can be a nozzle having at least onemetering hole of a unique dimension for a given nozzle design.

In some aspects, a method for identifying a consumable of a thermalprocessing torch, the torch including a plasma chamber defined by anelectrode and a nozzle, can include directing an inlet flow of a gasthrough a gas supply valve and a gas supply line to the plasma chamber,wherein the gas supply line has a regulator and a plasma off-valvecoupled thereto; adjusting the inlet flow of the gas until a thresholdpressure associated with the plasma chamber is reached; manipulating avent valve coupled to a vent line connected to the plasma chamber tolimit an outlet flow of the gas from the plasma chamber before thethreshold pressure value is reached; determining at least one of: (i) afirst value of a pressure of the inlet flow, (ii) a first value of aflow rate of the inlet flow, (iii) a first value of an off-valvepressure of the inlet flow, or (iv) a first value of a flow rate of theoutlet flow; manipulating the vent valve to permit the outlet flow ofthe gas from the plasma chamber after the threshold value is reached;determining at least one of: (i) a second value of the pressure of theinlet flow, (ii) a second value of the flow rate of the inlet flow,(iii) a second value of the off-value pressure of the inlet flow, or(iv) a second value of the flow rate of the outlet flow; and using thefirst or second value of the pressure of the inlet flow, the first orsecond value of the flow rate of the inlet flow, the first or secondvalue of the off-valve pressure of the inlet flow, or the first orsecond value of the flow rate of the outlet flow, or a combination ofany two or more such values, to identify the consumable.

Embodiments can include one or more of the following features.

In some embodiments, the threshold pressure can be a pressure of about4.0 pound per square inch (psig) in the plasma chamber or the vent. Theconsumable can be a nozzle having at least one metering hole of a uniquedimension. The method can include also using a flow sensor coupled tothe gas supply line to measure the flow rate of the inlet flow, the flowsensor being positioned between the gas supply valve and the regulator.The method can also include using a flow sensor coupled to the vent lineto measure the flow rate of the outlet flow, the flow sensor beingpositioned downstream from the vent valve. In some examples, the firstand second values of the pressure of the inlet flow can be measuredupstream from the regulator. In some examples, the first and secondvalues of the flow rate of the inlet flow are measured upstream from theregulator. In some examples, the first and second values of theoff-valve pressure of the inlet flow are measured downstream from theregulator. In some examples, the first and second values of the flowrate of the outlet flow can be measured at the vent line. In someexamples, manipulating the vent valve to permit the outlet flow of thegas from the plasma chamber can be performed prior to ignition of thetorch.

In some aspects, a system for identifying a consumable of a thermalprocessing torch includes a flow-restriction element associated with theconsumable and configured to receive a gas flow therethrough; a firstsensor to determine a first pressure of the gas flow through theflow-restriction element at a location upstream relative to theflow-restriction element; a second pressure determining device toestablish a second pressure of the gas flow through the flow-restrictionelement at a location downstream from the flow-restriction element; aflow meter for measuring a flow rate of the gas flow passing through theflow-restriction element; and a processor that uses the first pressure,the second pressure, and the flow rate to identify an operatingcharacteristic of the consumable.

Embodiments can include one or more of the following features.

In some examples, the system can include at least one radio-frequencyidentification (RFID) tag on, in, or in communication with, theconsumable for identifying the consumable. The second pressuredetermining device can be a device configured set the second pressure toatmospheric pressure. For example, the device can be configured set thesecond pressure to atmospheric pressure can include a vent valve. Thesecond pressure determining device can include a second pressure sensor.

In some aspects, a torch of a cutting system configured to identify aconsumable installed in the torch can include a vent passage fluidlyconnected to a fluid flow path of the torch; a flow detection deviceconfigured to detect a rate of fluid flow being expelled from the torchthrough the vent passage; and a vent valve fluidly connected to the ventpassage configured to limit the fluid flow from being expelled from thefluid flow path of the torch through the vent passage.

Embodiments can include one or more of the following features.

In some embodiments, the torch can also include a pressure sensorfluidly connected to the vent passage, where the pressure sensor isconfigured to detect a fluid pressure within the vent passage. The fluidflow path can include a plasma plenum region of the torch. The ventpassage can be fluidly connected to the fluid flow path by anidentifying orifice of the consumable installed in the torch.

In one aspect, a method is provided for configuring a first thermalprocessing system and a second thermal processing system. The methodincludes providing a first consumable for use in a first thermalprocessing torch and a second consumable for use in a second thermalprocessing torch. The first consumable and the second consumable havesubstantially identical physical characteristics. The first consumableis associated with a first signal device encoded with first data and thesecond consumable is associated with a second signal device encoded withsecond data. The method includes mounting the first torch with the firstconsumable in the first thermal processing system and the second torchwith the second consumable in the second thermal processing system. Themethod also includes sensing, by the first thermal processing system,the first data stored in the first signal device and sensing, by thesecond thermal processing system, the second data stored in the secondsignal device. The method further includes configuring, by the firstthermal processing system, a parameter of the first thermal processingsystem for operating the first torch based on the sensed first data byassigning a first value to the parameter. In addition, the methodincludes configuring, by the second thermal processing system, theparameter of the second thermal processing system for operating thesecond torch based on the sensed second data by assigning a second valueto the parameter. The second value can be different from the firstvalue.

In another aspect, a method is provided for assembling a first thermalprocessing torch and a second thermal processing torch. The methodincludes providing a first consumable with a first signal device locatedon or within a body of the first consumable and providing a secondconsumable with a second signal device located on or within a body ofthe second consumable. The method includes encoding the first signaldevice with first data associated with the first consumable. The firstdata correlates to a first value of a parameter of a first thermalprocessing system for operating the first torch. The method furtherincludes encoding the second signal device with second data associatedwith the second consumable. The second data correlates to a second valueof the parameter of a second thermal processing system for operating thesecond torch. The second value can be different from the first value.

In other examples, any of the aspects above can include one or more ofthe following features. In some embodiments, at least one of the firstor second data is independent of a detectable physical characteristic ofthe corresponding first or second consumable. At least one of the firstor second data can identify a type of the corresponding first or secondconsumable. The type of the corresponding consumable can include anozzle, a shield, an electrode, an inner retaining cap, an outerretaining cap, a swirl ring or a welding tip. In addition, at least oneof the first or second data can identify a serial number unique to thecorresponding first or second consumable. At least one of the first orsecond data can transmitted to the corresponding first or second thermalprocessing system as a pneumatic signal, a radio signal, a light signal,a magnetic signal or a hydraulic signal.

In some embodiments, at least one of the first signal device or thesecond signal device comprises a radio-frequency identification (RFID)tag. At least one of the first signal device or the second signal devicecan be located on or within a body of the corresponding first or secondconsumable. In some embodiments, the first or second signal device islocated at a surface of the body of the corresponding first or secondconsumable to minimize heat exposure during torch operation. The surfacecan be adjacent to a cooling mechanism, remote from a plasma arc, or inan o-ring channel of the corresponding first or second consumable, or acombination thereof.

In some embodiments, the parameter includes a torch height above aworkpiece, a flow rate of a plasma gas, a flow rate of a shield gas, atiming of plasma gas or current, or a process program for cutting theworkpiece. In some embodiments, the parameter is included in a set ofparameters configurable by at least one of the first or second thermalprocessing system to operate at least one of the first torch or secondtorch. In such a case, the first and second thermal processing systemscan assign a value to each of the set of parameters for operating therespective first and second torches.

In some embodiments, the method further includes providing a firstworkpiece and a second workpiece for processing by the first torch andthe second torch, respectively. The first and second workpieces are atleast substantially the same.

In some embodiments, sensing the first data stored in the first signaldevice further includes using a signal detector of the first thermalprocessing system to sense the first data. The signal detector can be anRFID reader. The signal detector can be located external to the firsttorch.

In some embodiments, the first and second thermal processing systems arethe same thermal processing system.

In another aspect, a method is provided for configuring a thermalprocessing system. The method includes providing a consumable for use ina thermal processing torch. The consumable has one or more physicalcharacteristics that facilitate installation into the torch. The methodincludes mounting the consumable in the torch, connecting the torch tothe thermal processing system and sensing, by the thermal processingsystem, data associated with the consumable. The method further includesconfiguring, by the thermal processing system, one or more parameters ofthe thermal processing system for operating the torch based on whetherthe sensed data satisfies a criterion.

In some embodiments, configuring one or more parameters of the thermalprocessing system includes preventing the thermal processing system fromoperating the torch if the data does not satisfy the criterion. The datacan identify a manufacturer of the consumable that does not match apermitted manufacturer.

In some embodiments, the data is encoded in a signal device coupled tothe consumable. Sensing can be performed by an RFID reader of thethermal processing system.

In some embodiments, the method further includes preventingconfiguration of one or more parameters of the thermal processing systemin the absence of any data sensed by the thermal processing system.

In some aspects, some embodiments may have one or more of the followingadvantages. Using the systems and methods described herein that includeidentifying thermal processing torch components, such as plasma torchconsumables (e.g., plasma torch nozzles, shields, retaining caps, orother consumables), by detecting changes in fluid flow (e.g., a drop influid pressure or flow) through features of the consumables, thermalprocessing torch systems can identify the consumables in a lessexpensive or a less complex manner than some other consumableidentification techniques and processes.

In some aspects, the systems and methods described herein can be used toidentify plasma torch consumables without requiring supplementalidentifying devices (e.g., visual markings, bar codes, readableinformation tags (RFID tag readers), or other identification devices).Without requiring supplemental identification devices, additionalsystems, such as systems that would read and interpret theidentification devices, such as camera vision systems, barcode readingsystems, or RFID reading systems can, in some cases, be omitted fromplasma torch systems, resulting in a less expensive, less complicatedplasma torch system. Additionally, using the identification systems andmethods described herein, consumables typically need not be modified toinclude the identifying devices, resulting in less expensive torchconsumables. Further, since the methods described herein essentiallyutilize only geometry of one or more features of a consumable toidentify the consumable, previously manufactured consumables can bemounted onto a plasma torch system and identified, which may not bepossible with identification techniques that utilize supplementalidentification devices. That is, in some cases, the systems and methodsdescribed herein actually identify physical features of the consumablesas opposed to merely reading or detecting an identifying device in or onthe consumable.

It should also be understood that various aspects and embodiments of theinvention can be combined in various ways. Based on the teachings ofthis specification, a person of ordinary skill in the art can readilydetermine how to combine these various embodiments. For example, in someembodiments, any of the aspects above can include one or more of theabove features. One embodiment of the invention can provide all of theabove features and advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an exemplary plasma arc torch.

FIG. 2 is a schematic diagram of an exemplary communication network.

FIG. 3 is a cross-sectional view of an exemplary plasma arc torchillustrating an altered geometry of various consumable components of theplasma arc torch.

FIG. 4 is a schematic diagram of an exemplary thermal processing systemusing the communication network of FIG. 2 to control the operation of athermal processing torch.

FIG. 5 is a diagram of another exemplary thermal processing system usingthe communication network of FIG. 2 to control the operation of athermal processing torch.

FIGS. 6A and 6B are flow charts illustrating exemplary operations of thecommunication network of FIG. 2.

FIG. 7 is a schematic diagram of an exemplary torch gas delivery systemincluding flow detection devices for identifying consumable componentsinstalled within a torch of the exemplary torch system.

FIG. 8 is a cross-sectional view of an exemplary plasma arc torchillustrating geometric features within the plasma arc torch that can beutilized for identifying consumable components installed within a torch.

FIG. 9 is a flow chart illustrating an exemplary method for identifyinga consumable component of a thermal processing torch by measuring gasflow changes through a feature of the consumable component.

FIG. 10 is a flow chart illustrating another exemplary method foridentifying a consumable component of a thermal processing torch bymeasuring gas flow changes through a feature of the consumablecomponent.

FIG. 11 is a flow chart illustrating another exemplary method foridentifying a consumable component of a thermal processing torch bymeasuring gas flow changes through a feature of the consumablecomponent.

FIG. 12 is an example lookup table which can be used to identify aconsumable component based gas flow characteristics of a thermalprocessing torch system in which the consumable component is installed.

DETAILED DESCRIPTION

In some aspects, thermal processing torch systems (e.g., plasma torchsystems) can identify torch components (e.g., consumable components) bydirecting a fluid flow (e.g., a coolant fluid flow or a plasma gas flow)through a feature of the consumable and detecting changes in the flowproperties (e.g., fluid pressure and fluid flow rate) of the fluid flowexiting feature of the consumable.

FIG. 1 is a cross-sectional view of an exemplary plasma arc torch 100including a torch body 102 and a torch tip 104. The torch tip 104includes multiple consumables, for example, an electrode 105, a nozzle110, a retaining cap 115, a swirl ring 120, and a shield 125. The torchbody 102, which has a generally cylindrical shape, supports theelectrode 105 and the nozzle 110. The nozzle 110 is spaced from theelectrode 105 and has a central exit orifice mounted within the torchbody 102. The swirl ring 120 is mounted to the torch body 102 and has aset of radially offset or canted gas distribution holes 127 that imparta tangential velocity component to the plasma gas flow, causing theplasma gas flow to swirl. The shield 125, which also includes an exitorifice, is connected (e.g., threaded) to the retaining cap 115. Theretaining cap 115 as shown is an inner retaining cap securely connected(e.g., threaded) to the nozzle 110. In some embodiments, an outerretaining cap (not shown) is secured relative to the shield 125. Thetorch 100 can additionally include electrical connections, passages forcooling, passages for arc control fluids (e.g., plasma gas), and a powersupply. In some embodiments, the consumables include a welding tip,which is a nozzle for passing an ignited welding gas.

In operation, plasma gas flows through a gas inlet tube (not shown) andthe gas distribution holes 127 in the swirl ring 120. From there, theplasma gas flows into a plasma chamber 128 and out of the torch 100through the exit orifice of the nozzle 110 and the shield 125. A pilotarc is first generated between the electrode 105 and the nozzle 110. Thepilot arc ionizes the gas passing through the nozzle exit orifice andthe shield exit orifice. The arc then transfers from the nozzle 110 to aworkpiece (not shown) for thermally processing (e.g., cutting orwelding) the workpiece. It is noted that the illustrated details of thetorch 100, including the arrangement of the components, the direction ofgas and cooling fluid flows, and the electrical connections, can take avariety of forms.

Different operating processes often require different shield and/orplasma gas flow rates, which require different sets of consumables. Thisleads to a variety of consumables being used in the field. Using thecorrect consumables and matching them appropriately is necessary toachieve optimal cutting performance. Consumable mismatch (e.g., using aconsumable made for operation at 65 Amps in a torch that is beingoperated at 105 Amps) can result in poor consumable life and/or poorperformance of the plasma arc torch.

FIG. 2 shows an exemplary communication network 200 of the presentinvention. The communication network 200 includes one or more signaldevices 202, each assigned to a consumable of a thermal processingtorch, such as the plasma arc torch 100 of FIG. 1. Exemplary consumablesinclude the electrode 105, the nozzle 110, the retaining cap 115, theswirl ring 120, and the shield 125. In some embodiments, a signal device202 is an electrically writable device configured to transmitinformation about a consumable in the form of one or more signals. Forexample, the signal device 202 can be a radio-frequency identification(RFID) tag or card, bar code label or tag, integrated circuit (IC)plate, or the like. In some embodiments, a signal device 202 is adetector (e.g., a sensor) for detecting a physical characteristic of theconsumable and transmitting the detected information in the form of oneor more signals. The communication network 200 also includes at leastone receiver 204 for (i) receiving signals transmitted by the signaldevices 202, (ii) extracting data conveyed by the signals, and (iii)providing the extracted data to a processor 206 for analysis and furtheraction. The processor 206 can be a digital signal processor (DSP),microprocessor, microcontroller, computer, computer numeric controller(CNC) machine tool, programmable logic controller (PLC),application-specific integrated circuit (ASIC), or the like.

In some embodiments, each signal device 202 is encoded with informationpertaining to the consumable to which the signal device 202 is assigned.The encoded information can be generic or fixed information such as theconsumable's name, trademark, manufacturer, serial number, and/or type.The encoded information, for example, can include a model number togenerally indicate that the consumable is a nozzle. In some embodiments,the encoded information is unique to the consumable, such as metalcomposition of the consumable, weight of the consumable, date, timeand/or location at which the consumable was manufactured, personnelresponsible for the consumable, and the like. As an example, the encodedinformation can provide a serial number, which is unique to each torchcomponent manufactured, to distinguish, for example, nozzle Type A,Serial #1 from nozzle Type A, Serial #2.

In some embodiments, information is encoded to a signal device 202 atthe time of manufacture of the corresponding consumable. Information canalso be encoded to a signal device 202 during the lifetime of theconsumable, such as after each consumable use. Such information caninclude the date, time and location of consumable use, any abnormalitiesdetected during use, and/or consumable conditions after use so that alog can be created to predict a failure event or end-of-life eventassociated with the consumable.

Information encoded to a signal device 202 can also specify operatingparameters. For example, for a signal device 202 associated with theshield 125, data encoded to the signal device 202 can indicate the typeof shield gas and/or the appropriate gas flow rate for the shield 125.In some embodiments, encoded data of a signal device 202 providesinformation about other related torch components. For example, encodeddata can identify other torch components that are compatible with theassigned consumable, assisting with installation of the entireconsumable set in a torch to achieve certain performance metrics.

In some embodiments, a signal device 202 includes information about thecorresponding consumable independent of a detectable physicalcharacteristic of the consumable. Examples of detectable physicalcharacteristics of the consumable include magnetic properties, surfacereflectivity, density, acoustic properties and other tactile features ofthe consumable measured by a detector installed in the torch. Therefore,examples of consumable data independent of a detectable physicalcharacteristic of the consumable can include consumable name, type,manufacturer, manufacturing date, manufacturing location, serial number,or other non-tactile features of a consumable. In some embodiments, thesignal device 202 stores pre-collected information of the consumable,including physical characteristics, before it is installed into thetorch, but the signal device 202 is not configured to actively measureor detect the physical characteristics. However, the signal device 202can store physical characteristics about the consumable measured ordetected by another device, such as by a sensor. Generally, the signaldevice 202 is used mainly for data storage purposes.

In some embodiments, the signal device 202 is located inside or on thetorch 100. For example, the signal device 202 can be attached to asurface of a consumable that is ultimately installed inside of the torchtip 104. The signal device 202 can also be attached to a componentinside of the torch 100 other than the assigned consumable. For example,while a signal device 202 is assigned to store data about the electrode105, the signal device 202 can be affixed to a surface of the retainingcap 115. In some embodiments, the signal device 202 is coupled to anexternal source that is not physically associated with the torch 100.For example, the signal device 202 can be attached to a package used tostore the consumable and is remote from the consumable once it isinstalled in the torch 100. If a signal device 202 is located inside ofthe torch 100, the surface to which the signal device 202 is attachedcan be selected to reduce or otherwise minimize heat exposure duringoperation of the torch 100. For example, the signal device 202 can belocated near a cooling mechanism, away from the plasma arc, and/or in ano-ring channel of the torch 100 to reduce or minimize heat exposure. Inaddition, the signal device 202 can be coated with a heat protectivematerial to reduce the likelihood that the device will overheat duringtorch operation. Generally, the signal device 202 can be situated, suchas being shielded by another torch component, to minimize exposure tothermal energy, radiation, damaging gases (e.g., ozone), and/orhigh-frequency energy.

In some embodiments, a signal device 202 is designed to be durable,i.e., functional during and after one or more torch ignitions. In someembodiments, a signal device 202 is disposable after each torch use orafter several uses. In some embodiments, a signal device 202 is writableonce, for example, to encode information about a consumable when theconsumable is first manufactured. In some embodiments, a signal device202 is writable multiple times, such as throughout the lifespan of thecorresponding consumable.

In the communication network 200, the signal device 202 can wirelesslytransmit its stored information to the receiver 204 in the form of oneor more signals. The receiver 204 is adapted to process these signals toextract pertinent data about the consumable and forward the data to theprocessor 206 for analysis. In some embodiments, the receiver 204 islocated in or on the plasma arc torch 100. For example, the receiver 204can be located in the torch body 102. In some embodiments, the receiver204 is at a location external to the torch 100, such as attached to apower supply module, a gas console, the processor 206, etc.

In some embodiments, at least one of the signal devices 202 is an RFIDtag and the receiver 204 is a reader used to interrogate the RFID tag.In such embodiments, the RFID tag includes a microchip for storinginformation and an antenna for receiving and transmitting RF signals.The reader can include (1) an antenna for transmitting RF signals to theRFID tag to interrogate the tag and (2) components for decoding aresponse transmitted by the RFID tag before forwarding the response tothe processor 206. The RFID tag can be either active or passive. Anactive RFID tag includes a battery to produce a stronger electromagneticreturn signal to the reader, thereby increasing the possibletransmission distance between the RFID tag and the reader. The distancebetween an RFID tag and a reader can be from less than one inch to 100feet or more, depending on the power output, the radio frequency usedand the type of material through which the RF signals need to travel. Inone example, the distance between an RFID tag and an antenna of acorresponding reader can be about 2-4 cm. A reader antenna and remainingreader components do not need be in the same packaging. For example, thereader antenna can be located on or inside of the torch body 102 whilethe remaining reader components are external to the torch 100. Using anRFID tag is advantageous because it does not require direct contact(e.g., via wires) or direct line of sight (e.g., via optical signals)with the reader and is well suited for use in harsh environments.

In some embodiments, a signal device 202 is a detector (e.g., a sensor)for detecting at least one physical marker of the consumable foruniquely identifying the consumable by its type or individually. Thephysical marker can be a physical alteration of the consumable, forexample. As shown in FIG. 3, identification of a consumable is achievedby altering the geometry of the consumable such that, when it isinstalled in the torch 100, it affects the wall of an adjacent coolantpassageway 402, which in turn alters the rate of a coolant flowingtherethrough. Specifically, the altered section of the coolantpassageway 402 can restrict the rate of the coolant flow. A signaldevice 202 can be used to measure the pressure change as a function ofthe coolant flow rate. Hence, the measured coolant pressure changeserves as an identification of the consumable. In another example asshown in FIG. 3, an auxiliary vent line 404 that is connected to a valveand a flow meter is attached to the nozzle 110 to identify the nozzle110. The valve is opened prior to plasma arc ignition and the auxiliaryvent line flow rate is measured by a signal device 202 as a function ofplasma pressure during a purge cycle. Therefore, the measured flow rateserves as an identification of the nozzle 110. In another example, oneor more uniquely sized metering holes (not shown) can be drilled intothe outer retain cap to identify the cap once it is installed in thetorch 100. The size of each metering hole is configured to uniquelyaffect the off-valve pressure and/or the flow rate of the shield gas.Therefore, these measurements, taken by a signal device 202 in apre-flow routine prior to pilot arc ignition, serve to identify theouter retaining cap.

In yet another example, the shield 125 can be identified by measuringthe consumable's length relative to a reference torch datum. In anexemplary measurement process, a torch height controller is used todetermine the height at which a known torch fires and begins to cut aworkpiece. This height can serve as the reference torch datum. Then,after installing an unidentified consumable into the torch, the heightrelative to the reference datum is determined. Therefore, simplecalculations involving the two heights can be used to determine therelative length of the unidentified consumable. In turn, the relativeconsumable length can be used to identify the consumable by, forexample, referencing a looking-up table that correlates relativeconsumable lengths to consumable parts.

In some embodiments, a signal device 202 is a barcode that providesoptical machine-representation of data about the correspondingconsumable. A barcode can be read by the receiver 204 in the form of abarcode reader. Generally, a signal device 202 can convey data about aconsumable in the form of any machine readable signals, including radiosignals, optical or other light-based signals (e.g., infrared signals orultraviolet signals), magnetic signals, pneumatic signals, or hydraulicsignals.

In some embodiments, a single signal device 202 is assigned to eachconsumable of a torch to transmit pertinent information about thecorresponding consumable. In some embodiments, two or more signaldevices 202 are assigned to the same consumable to transmit differentinformation about that consumable. For example, one signal device 202can transmit information unique to the consumable type, such as themodel number and operating parameters for the consumable type, whileanother signal device 202 can transmit information unique to theconsumable itself, such as weight and usage history of the consumable.In some embodiments, the signal devices 202 in the communication network200 employ different modes of data transmission. For example, while onesignal device 202 transmits data as RF signals, another signal device202 transmits data as optical signals. In some embodiments, the network200 includes multiple receivers 204. Each receiver 204 is configured(e.g., tuned) to read signals from one or more of the signal devices 202and transmit the extracted data to the processor 206. In someembodiments, a single receiver 204 is used to read signals from allsignal devices 202 in the communication network 200. The processor 206thus can simultaneously process data associated with multipleconsumables.

FIG. 4 is an exemplary thermal processing system 300 using thecommunication network of FIG. 2 to control the operation of a thermalprocessing torch, such as the plasma arc torch 100 of FIG. 1. The plasmaarc torch 100 can include one or more consumables including the nozzle110, the electrode 105, the shield 125, the inner retaining cap 115 andan outer retaining cap 302. At least one signal device 202 is assignedto at least one of the consumables for transmitting information aboutthe corresponding consumable to the processor 206 via the receiver 204.The system 300 also includes a power supply 304 for providing theelectrical current necessary to generate plasma arc in the torch 100.Data collected from the signal devices 202 about the respectiveconsumables can be used by the processor 206 to control and optimize theoperation of at least one of the plasma power supply 304, the motors anddrivers 306, the gas console 308, the height controller 310 and thenesting software 312.

The processor 206 can be located inside or outside of the plasma arctorch 100. In some embodiments, the processor 206 is housed in the powersupply 304. In some embodiments, each of the plasma power supply 304,the motors and drivers 306, the gas console 308, the height controller310 and the nesting software 312 houses at least one processor forprocessing data from the signal devices 202 to control the functions ofthe respective module 304, 306, 308 or 310.

Based on the information collected from the signal devices 202, theprocessor 206 can regulate many plasma system functions simultaneouslyor near simultaneously and in real-time or near real-time. These systemfunctions include, but not limited to, start sequence, CNC interfacefunctions, gas and operating parameters, and shut off sequences. In someembodiments, the processor 206 uses consumable information toautomatically set various parameters of the system 300. In someembodiments, the processor 206 uses consumable information to verifywhether certain preset parameters of the system 300 are compatible withthe consumables inside of the torch 100. As an example, based on thedata collected about the multiple consumables of the torch 100, theprocessor 206 can control and verify one or more of the following systemcomponents: (i) settings of the power supply 304 for regulating power tothe torch 100, (ii) settings of the nesting software 312 for processinga workpiece, (iii) settings of the gas console 308 for controllingshield and/or plasma gases supplied to the torch 100, (iv) settings ofthe height controller 310 for adjusting the height between the torch 100and the workpiece, and (v) settings of various motors and drivers 306.

In some embodiments, based on the data collected from one or more signaldevices 202, the processor 206 interacts with the nesting software 312to automatically select a cutting program that sets parameters forprocessing a workpiece, such as the cutting speed, direction, paths,nesting sequences, etc. The cutting program can also define the gastypes, gas pressure and/or flow settings and height control settings forthe torch in view of the collected consumable data. Traditionally, whena set of consumables is assembled into a torch, an operator needs tomanually configure the nesting software 312 to create the cuttingprogram for the torch by supplying information to the software includingthe type and thickness of the workpiece material being processed, thetype of gas being used, and the current rating of the consumable set. Inparticular, the operator needs to manually input into the processor 206the current rating of the consumable set. In the present invention,because the current rating information for each consumable is stored inat least one signal device 202, the processor 206 can electronicallycollect such information from the one or more signal devices 202 andautomatically determine the appropriate current setting without userinput.

In some embodiments, based on the collected consumable data, theprocessor 206 selects a suitable cutting program from the nestingsoftware 312 by taking into consideration of consumable data from thesignal devices 202 and user-input operating parameters, including thecharacteristics of the workpiece being cut and the desired cut shape.For example, an operator can first send a generic program file to thenesting software 312. The generic program file specifies, for eachworkpiece thickness, variable cut speeds, gas flows, kerf compensations,torch heights, etc. that change with different consumable parts. Thus,after identifying the consumables using the signal devices 202, theprocessor 206 interacts with the generic program file to configure acutting program for the torch. In some embodiments, after a cuttingprogram is created, the processor 206 uses consumable data collectedfrom the signal devices 202 to verify whether correct consumables areinstalled into the torch that are appropriate for the program.Alternatively, the processor 206 can instruct the nesting software 312to automatically set or correct parameters of the program to enhancecompatibility with the consumables loaded into the torch. For example, aconsumable requiring 400 A current has larger kerfs and lead-ins incomparison to a consumable requiring 130 A current. Accordingly, thenesting software 312 can select fewer parts to fit on a nest of theprogram if the 400 A consumable is loaded into a torch.

In some embodiments, based on the data collected from one or more signaldevices 202, the processor 206 can manipulate a gas console 308 tocontrol flow of plasma and shield gases to the torch 100 by verifyingand adjusting the gas console settings. The gas console 308 housessolenoid valves, flow meters, pressure gauges, and switches used forplasma and shield gas flow control. For example, the flow meters areused to set the pre-flow rates and cut flow rates for the plasma andshield gases. The gas console 308 can also have a multi-inlet gas supplyarea where the plasma and shield gases are connected. A toggle switchcan be used to select the desired gases. The plasma and shield gases aremonitored by gas pressure sensors. In one example, a signal device 202associated with the shield 125 of the plasma arc torch 100 can storeinformation about the type and composition of one or more shield gasessuitable for use with the shield 125, along with the optimal flow ratesetting of the shield gases. Based on this data, the processor 206 caninteract with the gas console 308 to provide the plasma arc torch 100with the appropriate shield gas at the optimal flow rate.

In some embodiments, based on the data collected from one or more signaldevices 202, the processor 206 manipulates the torch height controller310, which sets the height of the torch 100 relative to the workpiece.The torch height controller 310 can include a control module to controlan arc voltage during cutting by adjusting the standoff (i.e., thedistance between the torch 100 and the work piece) to maintain apredetermined arc voltage value. The torch height controller 310 canalso include an external control module to control the standoff. Thetorch height controller 310 can further include a lifter, which iscontrolled by the control module through a motor or driver 306, to slidethe torch 100 in a vertical direction relative to the workpiece tomaintain the desired voltage during cutting. In one example, based onthe data collected from the consumables of a torch, the torch heightcontroller 310 can automatically determine the height to position thetorch relative to the top of a workpiece. Therefore, the torch heightcontroller 310 does not need to perform a height sense in order to setan appropriate pierce height and cut height before beginning arc voltagecontrol. In some embodiments, based on the data collected from one ormore signal devices 202, the processor 206 manipulates the motors anddrivers 306 to move the torch 100 laterally in relation to the surfaceof the workpiece. The processor 206 can also manipulate the heightcontroller 310 to move the torch 100 vertically in relation to thesurface of the workpiece.

In some embodiments, the processor 206 is configured to prevent thethermal processing system 300 from commencing an operation on theworkpiece if it determines that the consumables installed in the torch100 are mismatched with each other, not compatible with the thermalprocessing system 300 or inconsistent with other pre-selected operatingparameters input by an operator. If such a determination is made, theprocessor 206 can trigger an audio or visual alert indicating to theoperator that one or more of the connected consumables are unsupportedand that the consumables should be replaced or operator inputs should berevised. Additionally, the processor 206 can prevent initiation of anoperation if an alert is triggered. For example, the processor 206 canstop torch operation if the current setting of the shield 125, which isconveyed to the processor 206 by a signal device 202 assigned to theshield 125, is different from the current setting of the nozzle 110,which is conveyed to the processor 206 by a different or the same signaldevice 202 corresponding to the nozzle 110.

In some embodiments, the processor 206 is configured to prevent thethermal processing system 300 from operating if it determines that atleast one of the consumables installed in the torch 100 is notmanufactured or otherwise supported by an accepted manufacturer. Forexample, the processor 206 can stop torch operation if it does notrecognize the manufacturer identification, serial number and/or partsnumber conveyed by a signal device of a consumable. Hence, the thermalprocessing system 300 can be used to detect and prevent the use ofinferior or counterfeit consumables.

In some embodiments, the processor 206 recommends one or more remedialactions to the operator to address alarm situations. For example, theprocessor 206 can suggest one or more consumables to install in thetorch 100 to avoid potential mismatch with other components of thermalprocessing system 300. The processor 206 can suggest suitable types ofworkpiece for processing based on the ratings of the installedconsumable set. The processor 206 can recommend a cutting sequence thatreconciles the settings of the installed consumables with settingsprovided by the operator.

Generally, the signal devices 202 can store information about torchcomponents other than consumables. For example, the signal devices 204can store information about the torch body 102 or about one or moreleads. Therefore, as one in the art will fully appreciate, the exemplarycommunication network 200 of FIG. 2 and the configuration of FIG. 3 canbe easily adapted to store information about any torch component.

FIG. 5 is another exemplary thermal processing system 500 using thecommunication network 200 of FIG. 2 to influence, control, or otherwiseaffect the operation of a thermal processing torch, such as the plasmaarc torch 100 of FIG. 1. The thermal processing system 500 includes acomputerized numeric controller (CNC) 502, a power supply 504, anautomatic process controller 508, a torch height controller 512 and adriver system 516, which are similar to the processor 206, the powersupply 304, the gas console 308, the height controller 310 and the motorand drivers 306, respectively, of the operating system 400. In addition,the thermal processing system 500 includes a cutting table 520,

To operate the thermal processing system 500, an operator places aworkpiece on the cutting table 520 and mounts the torch 100 into thetorch height controller 512, which is attached to the gantry 522. Thedriver system 516 and the height controller 512 provide relative motionbetween the tip of the torch 100 and the workpiece while the torch 100directs plasma arc along a processing path on the workpiece. In someembodiments, at least one receiver 204 is attached to a component of thethermal processing system 500 to receive signals emitted by at least onesignal device 202 associated with one or more consumables of the torch100. For example, a receiver 204 can be coupled to the gantry 522 toread signals from the torch 100 after the torch 100 is installed intothe system 500. The receiver 204 can also be attached to other systemcomponents including, for example, the CNC 502, the height controller512, the driver system 516 or the cutting table 520. In someembodiments, the receiver 204 is mounted inside or on the surface of thetorch 100. In some embodiments, multiple receivers 204 are disbursedthroughout the system 500 external to the torch 100, each receiver 204being tuned to read data concerning one or more specific consumables ofthe torch 100. For example, while one receiver 204 is used to receivedata from a signal device 202 assigned to a nozzle, another receiver 204is used to read data from a signal device 202 assigned to a shield.After obtaining information from a signal device 202, the receiver 204can transmit the information to the CNC 502, which uses the informationto configure the thermal processing system 500 for processing.

In some embodiments, signal devices 202 associated with two sets ofphysically identical (or at least substantially identical) consumablesare encoded with different consumable information and installed into twodifferent torches. For example, a signal device for the nozzle of onetorch can be encoded with Serial Number A while another signal devicefor the nozzle of a second torch can be encoded with Serial Number B,even though the two nozzles are manufactured to identical designspecifications. The nozzles are installed into the respective torches.The two torches are installed into their respective thermal processingsystems, and the receiver 204 of each thermal processing system canreceive consumable data from the signal device 202 of each torch. Insome embodiments, based on the different consumable data, the thermalprocessing systems are adapted to suitably adjust one or more operatingparameters of the systems so as to operate the torches differently, evenwhen the consumables of the two torches are physically identical to eachother and all extraneous factors are the same (e.g., the material typeand thickness of the workpieces being processed by the two torches arethe same). For example, based on the different consumable data, theconsumable data can cause the thermal processing systems to interactwith the respective nesting software 312 to enable different cuttingprograms for the two torches and/or interact with the respective heightcontrollers 512 to set different heights for the two torches. Ingeneral, based on the different consumable data, one thermal processingsystem corresponding to one torch can be configured to include featuresA, B, or C while a second thermal processing system corresponding to theother torch can be configured to include features X, Y or Z. In someembodiments, the same thermal processing system can be configured indifferent manners depending on the consumable data encoded in the twotorches. Exemplary features customizable by a thermal processing systeminclude: plasma gas flow and timing, shield gas flow and timing, cuttingcurrent and timing, pilot arc initiation and timing, torch height abovethe surface of a workpiece and/or torch lateral motion parallel to thesurface of a workpiece.

In some embodiments, a thermal processing system is adapted to activatea proprietary process for operating a torch only after determining thatthe information about one or more consumables in the torch satisfiescertain criteria, such as being manufactured by a specific manufacturer.This information is stored on one or more signal devices 202 coupled tothe consumables, and may be accessed by the thermal processing system.Therefore, if the consumables are produced by a different manufacturerand do not have the correct (or any) information encoded in their signaldevices 202, the thermal processing system does not initiate theproprietary process, even if the “incorrect” consumables are physicallyidentical to the consumables produced by the desired manufacturer. Insome embodiments, a thermal processing system does not initiate aproprietary process when the system does not sense any data from thetorch consumable. This can occur if, for example, the consumable is notassociated with a signal device 202 or the signal device is defective.Therefore, a configuration process executed by a thermal processingsystem can simply involve the system detecting whether a consumable isassociated with the correct data and/or alert the operator if incorrector no information is detected from the consumable. An exemplary alertinclude an alarm, a visual indicator, or a combination thereof. Inaddition, the system can prevent operation of a torch in response todetecting incorrect or no information from the consumable.

FIGS. 6A and 6B are flow diagrams illustrating exemplary operations ofthe communication network 200 of FIG. 2. FIG. 6A illustrates anexemplary process for assembling thermal processing torches to includeone or more consumables and signal devices 202. Specifically, at step602, two consumables are provided, with both consumables manufacturedbased on the same, or substantially the same, physical specifications.As a result, the two consumables have identical, or substantiallyidentical, physical characteristics. A signal device 202, such as anRFID tag, can be coupled to each of the two consumables. Each signaldevice 202 can be located on or within the body of the correspondingconsumable. At steps 604A and 604B, the signal device 202 for eachconsumable is encoded with data that can be used to determine systemconfiguration settings for operating the corresponding torch. Forexample, one consumable can be encoded with data A while the otherconsumable can be encoded with data B, where data A and data B can beused to set one or more operating parameters of the respective thermalprocessing systems for operating the respective torches. In someembodiments, data A and data B include different serial numbers assignedto the respective consumables, which correlate to different values forsetting the operating parameters of the thermal processing systems.Exemplary operating parameters associated with a thermal processingsystem include a height of the torch above a workpiece, a flow rate of aplasma gas through the torch and a cutting program for processing aworkpiece using the torch. At steps 608A and 608B, each consumablemanufactured at step 602, along with its respective signal devices 202,is assembled into a torch.

FIG. 6B illustrates an exemplary process for configuring two thermalprocessing systems, such as the thermal processing system 400 of FIG. 4or the thermal processing system 500 of FIG. 5, in preparation foroperating the two torches of FIG. 6A. At steps 612A and 612B, thetorches are mounted into their respective thermal processing systems.With reference to the thermal process system 500, each torch can bemounted on the gantry 522 above the cutting table 520. At steps 614A and614B, receivers 204 of the respective thermal processing systems areused to read the consumable data encoded in the signal devices 202 ofthe corresponding consumables. For example, at step 614A, a receiver 204can read data A from the signal device 202 associated with theconsumable of the first torch. At step 614B, another receiver 204 canread data B from the signal device 202 of the consumable of the secondtorch. At steps 618A and 618B, the receivers 204 of the thermalprocessing systems forward the data to the respective CNC's of thethermal processing systems, which set and/or adjust certain parametersof the corresponding thermal processing systems based on the receiveddata to operate the corresponding torches. In some embodiments, thedifference in the encoded data for the two consumables translates todifferent values for setting the operating parameters of the thermalprocessing systems, even though the consumables are physically identicalto each other. In some embodiments, the thermal processing systemsassign the same values to the operating parameters despite thedissimilarity in the encoded data.

In some embodiments, the method described with reference to FIG. 6B isimplemented by a single thermal processing system, which is adapted toset operating parameters of the system for operating both torches eithersimultaneously or sequentially (i.e., one torch at a time).

In addition, as one in the art will fully appreciate, the inventiondescribed herein is not only applicable to plasma cutting devices, butalso welding-type systems and other thermal processing systems. In someembodiments, the invention described herein is configured to operatewith a variety of cutting technologies, including, but not limited to,plasma arc, laser, oxy fuel, and/or water-jet technologies. For example,the signal devices 202 can be coupled to one or more consumablesconfigured to operate with one or more of the cutting technologies. Theprocessor 206, using information transmitted by the signal devices 202,can determine whether the consumables installed in a torch arecompatible with the specific cutting technology. In some embodiments,based on the selected cutting technology and the consumable information,the processor 206 can set or adjust operating parameters accordingly,such as the height of the cutting head above the workpiece, which canvary depending on the cutting technology and the consumables.

As an example, it is known to use water-jet systems that produce highpressure, high-velocity water jets for cutting various materials. Thesesystems typically function by pressurizing water or another suitablefluid to a high pressure (e.g., up to 90,000 pounds per square inch ormore) and force the fluid through a small nozzle orifice at highvelocity to concentrate a large amount of energy on a small area. Anabrasive jet is a type of water jet, which can include abrasivematerials within the fluid jet for cutting harder materials. In someembodiments, the signal devices 202 are attached to consumables of awater jet system, such as to a water jet orifice, a mixing tube used tomix abrasive particles with fluid, and/or one or more high pressurecylinders, pump seals or valves. A signal device 202 associated with awater jet orifice can, for example, identify the size of the orifice,track the hours of operation, and can also indicate other consumablesthat are suitable for use with a particular orifice. Identification ofparticular consumable set combinations for a given water jet system canalso be performed, to verify compatibility with a given system or to setoperating conditions and parameters, such as water pressure, or abrasivetypes or amounts.

In some aspects, thermal cutting systems, such as plasma arc cuttingtorches can include devices and features that enable detection oridentification of consumable components installed within the torch bydirecting a gas flow through the torch (e.g., through a feature of theconsumable component) and detecting the manner in which the gas flow isaltered as it flows through the torch and the consumable component. Forexample, in some embodiments, a gas flow is directed through features(e.g., flow-restriction elements including metering holes, vent holes,gas exit orifices, flow distribution passages, or other features)arranged on a consumable (e.g., a nozzle or a swirl ring). Based onobserved changes in one or more fluid flow characteristics (e.g., gaspressure or flow rate) upstream and downstream of the features, the sizeof the features, and therefore the consumable itself, can be identified.As discussed below, the following described methods can also beimplemented using water jet systems to identify various componentsinstalled in the system.

To monitor gas flow through a material processing system (e.g., a plasmaarc torch system or a water jet system), the system can include variousgas flow detection devices, such as valves, pressure detectors, pressureregulators, gas flow meters, and other devices, which can all be fluidlyconnected to one another by gas tubing, such as semi-rigid tubing orflexible hose. Referring to FIG. 7, in some embodiments, a fluid (e.g.,gas) delivery system 700 for delivering gas to a material processingdevice (e.g., a torch (e.g., a torch head)) 701 can include a fluidsupply (e.g., a compressed air tank or air compressor) 702, a supplyoff-valve 704, a supply pressure sensor 706, a supply gas flow detector708 (as illustrated with a dashed line box, the supply pressure sensor706 and the supply gas flow detector 708 can be a single component(e.g., a pressure compensated flow meter)), a supply gas pressureregulator 710, an off-valve pressure sensor 712, typically a ventpressure sensor (e.g., torch plasma plenum pressure sensor) 714, a ventoff-valve 716, a torch vent gas flow detector 718, and a torch vent gasoutlet 720. The gas supply 702 is typically fluidly connected to a torchsystem control unit (e.g., a power supply), which can house the supplyoff-valve 704, the supply pressure sensor 706, and the supply gas flowdetector 708 (or the combined pressure compensated flow meter).

The supply gas pressure regulator 710 and the off-valve pressure sensor712 are typically located separately from the control unit, for example,disposed on or within a torch gas supply lead line connected to thecontrol unit for providing gas and electricity to a torch. In somecases, the supply gas pressure regulator 710 and the off-valve pressuresensor 712 are arranged near (e.g., within 10 feet of (e.g., within 6feet of)) the torch 701 connected to the lead line at an end oppositethe control unit. As discussed below, by arranging these componentscloser to the torch 701, gas pressure that is controlled and monitoredwithin the lead line by the supply gas pressure regulator 710 and theoff-valve pressure sensor 712 can more closely represent the actualpressure delivered to the torch.

As illustrated, these various components can be connected to one anotherby any of various structurally and chemically suitable tubes or hoses.Examples of suitable hoses include flexible hoses (e.g., flexibleplastic or rubber hoses), rigid tubing (e.g., rigid metal, plastic orcomposite tubing), or tubing made of a combination of flexible and rigidlayers, such as a flexible hosing having a braided outer component(e.g., a braided sheath). Some or all of these components can be incommunication (e.g., wireless or wired communication) with a controlunit (e.g., a processor within a torch system control unit) formonitoring and controlling the gas delivery system.

Based on the configurations of these various components, gas flows canexit the torch from one or more different areas. For example, when a gasflow G enters the torch head 701, a gas stream G1 is typically expelledout from the torch head (e.g., via the nozzle orifice). The gas streamG1 generally includes gas that would typically be used to generate aplasma stream and process a material. Additionally, when the gas flow Genters a flow restriction element, such as a distribution hole in aswirl ring 727 (shown in schematic form in FIG. 7), the gas flow G canbe divided into multiple flow channels to form the gas stream G1 and asecond gas stream G2. Therefore, for torch systems having a vent system,a second gas stream G2 can be directed by the swirl ring 727 (or a venthole of a nozzle as mentioned below) and be emitted from the torch viathe vent system based on whether or not certain components of the ventsystem (e.g., the vent off-valve 716) are opened or closed. Inparticular, in some embodiments, a gas stream G2 is emitted from thetorch head when the vent off-valve 716 is open. That is, the gas streamG2 can be caused by gas flowing within the various flow channels andorifices within the torch head. As illustrated schematically, gas flow Gcan enter the torch via the off-valve hose and be divided into the gasstream G1 and the gas stream G2 within the torch head while the gasflows through the consumable components arranged within the torch (e.g.,the swirl ring or the nozzle). For simplicity, the division of the gaswithin the torch into the gas stream G1 and gas stream G2 isschematically illustrated without showing the specific consumablecomponents. Alternatively or additionally, in some cases, gas flow G isdelivered to a nozzle from a swirl ring and a first portion (e.g., gasstream G1) can be directed to be expelled from the torch in the form ofplasma gas and a second portion (e.g., gas stream G2) can be directedthrough the nozzle through a vent region (as discussed below withrespect to FIG. 8), on to the flow restriction element, and out of thetorch through a vent passage.

In some embodiments, a system (e.g., the system 700) for identifying aconsumable component, such as a nozzle or a swirl ring, of a thermalprocessing torch includes a flow-restriction element (e.g., a nozzleorifice, a metering hole of a nozzle, a vent hole of a nozzle, or a gasdistribution hole of a swirl ring) that is associated with theconsumable and is configured to receive a gas flow therethrough, a firstsensor (e.g., the off-valve pressure sensor 712) to determine thepressure of the gas flow through the flow-restriction element at alocation upstream relative to the flow-restriction element, a secondpressure determining device to establish a pressure of the gas flowthrough the flow-restriction element at a location downstream from theflow-restriction element, a flow meter (e.g., the vent gas flow detector718) for measuring a flow rate of the gas flow passing through theflow-restriction element, and a control unit (e.g., processor) that usesthe first pressure, the second pressure, and the flow rate to identifyan operating characteristic of the consumable.

In some cases, the second pressure determining device can include apressure sensor (e.g., the vent pressure sensor 714) fluidly connectedto the torch vent, which can measure the pressure within the plasmaplenum, for example, when the vent valve is closed. Alternatively oradditionally, in some cases, the second pressure determining deviceincludes a vent valve (e.g., the vent off-valve 716) that is configuredto expose the location downstream from the flow-restriction element(e.g., the torch vent passage) to the atmosphere to set the pressure toatmospheric pressure. That is, in some cases, the second pressure is notexplicitly measured by one of the components of the gas delivery system,but is rather set to atmospheric pressure (e.g., 0 psig). As discussedbelow, such a configuration can permit identification of a consumableusing only one pressure sensor when the region downstream of the flowrestriction element can be exposed to atmospheric pressure, for example,by opening the vent valve 716.

Additionally, as described above, in some embodiments, the system caninclude at least one radio-frequency identification (RFID) tag affixedon, in or in communication with the consumable for identifying theconsumable.

To measure and control gas pressure within various gas passageways of atorch head, the gas passageways can be fluidly connected to gas flowmeasurement devices (e.g., gas pressure or flow sensors). Alternatively,in some cases, gas flow measurement devices can be arranged within thetorch head. Referring to FIG. 8, in some embodiments, a torch 800includes a consumable (e.g., nozzle) 803 having a flow-restrictionelement (e.g., a nozzle vent identification hole) 805. A plasma plenumchamber 802 defined within the nozzle can be fluidly connected to apressure sensor (e.g., the torch vent pressure sensor 714) so that gaspressure within the plasma chamber 802 can be monitored and measured.For example, when an off-valve pressure sensor 712 fluidly connected toa nozzle vent passage 806 (which is typically fluidly connected to avent pressure sensor 714, a vent off-valve 716, and a torch vent gasflow detector 718) is closed, a pressure lock can be generated withinthe nozzle vent 806 and the plasma plenum chamber 802. Therefore, thecommon pressure detected by the vent pressure sensor can indicate thepressure within the plasma plenum chamber. A gas supply region 804 istypically located at a position upstream from the consumable 803. Duringuse, gas (e.g., plasma cutting gas) can be delivered from the gasdelivery system 700 to the gas supply region 804 through flow directingpassages of the swirl ring. In the example illustrated, gas flows intothe plasma chamber of the nozzle 803 and at least a portion of the gasentering the plasma chamber can flow out of the nozzle 803 through anozzle vent region 808 and the vent hole (identification hole) 805. Insuch embodiments, the vent passage 806 can be considered a region thatis downstream of the flow restriction element 805.

As discussed herein, the gas flow properties observed at variouslocations within gas delivery systems can be used to identify theconsumable installed in the torch. For example, torch gas deliverysystems (e.g., the torch gas delivery system 700) can be used toimplement one or more various torch consumable component identificationmethods by manipulating and monitoring gas flow within the torch system.

For example, in some aspects, a gas flow (e.g., the gas flow G) can beprovided to the torch and a vent off-valve can be closed to establish apredetermined gas pressure within the plasma plenum and vent passage ofthe torch by adjusting a pressure of the gas flow provided to the torch.With the vent off-valve closed, gas pressure begins to build within thetorch plasma plenum region and the vent passage line so that gassubstantially only exits through the torch exit orifice (i.e., in theform of the gas stream G1). Once the predetermined gas pressure isestablished within the plasma plenum region and the vent passage line,the pressure and gas flow rate of the gas flow directed through theconsumable (e.g., the flow rate upstream of the consumable, such as theflow rate provided to the swirl ring) can be monitored and measured. Themeasured gas flow rates and pressures can be compared to known (orexpected) corresponding gas flows and pressures for various differentconsumables. Based on the comparison to known values as discussed belowin detail in the following examples, the type of consumable installed inthe torch can be identified.

In some embodiments, once the predetermined gas pressure within theplasma plenum and vent passage is established, the vent off-valve can beopened to expose the flow region downstream of the flow restriction(e.g., the vent passage line) to atmospheric pressure so that gas canexit the torch through the torch head (gas stream G1), as well asthrough the vent (to form gas stream G2). With the gas stream G1 and thegas stream G2 flowing from the torch, the pressure and flow rate of gasdirected to the consumable, as well as the gas flow through the vent canbe measured. Similarly, the measured pressure and gas flow values can becompared to typical expected values associated with certain consumablesto predict what type of consumable is installed in the torch. Theabove-described generic consumable identification methods can beimplemented in any of various configurations.

Referring to FIG. 9, in some aspects, an exemplary method (900) foridentifying a consumable of a thermal processing torch includes firstdirecting a gas flow through a flow-restriction element associated withthe consumable (e.g., a nozzle or a swirl ring) disposed within thethermal processing torch (902). For example, in some embodiments, gas isdelivered to a torch head from a gas supply (e.g., the gas supply 702)via a gas delivery system (e.g., the regulator 710). The gas can bedelivered to the torch head and directed through the flow-restrictionelement, such as an orifice associated with the consumable (e.g., anexit orifice of a nozzle (e.g., a plasma exit orifice), a gasdistribution hole of a swirl ring, or another vent or metering hole ofthe consumable). In some embodiments, different flow-restrictionelements can be used to identify different types of consumables. Forexample, when using a nozzle, the flow-restriction element can includean identifying vent hole or the plasma exit orifice of the nozzle andwhen using a shield, the flow-restriction element can include the ventholes of the shield. In some cases, a gas distribution hole can be usedto identify a swirl ring.

In some embodiments, the flow-restriction element comprises an absenceof a hole, for example, an absence of a vent hole on a nozzle. Forexample, a nozzle may not include an identifying vent hole such thatwhen a vent valve is open, which would be expected to cause gas flow tobegin flowing from the vent hole of the nozzle and out of the vent, nogas flow is detected by the vent flow detector. The lack of a detectedvent flow when the vent valve is open would therefore indicate that aconsumable without a vent hole is installed in the torch.

Next, a first pressure can be determined (904). For example, a pressureof the gas flow at a location upstream relative to the flow-restrictionelement can be determined. In some embodiments, the vent off-valve 716can be closed to allow a pressure to build within the vent region andthe plasma plenum, which can also cause the torch to substantially onlyproduce the gas stream G1. With the vent off-valve 716 closed, the firstpressure can be manually adjusted, for example using the pressureregulator 710, to set the pressure within the vent passage and theplasma plenum to a predetermined value. In some cases, the predeterminedpressure value can be about 4 psig or another predetermined pressurebased on the equipment's capabilities. Therefore, the pressure (e.g.,the first pressure) of the gas being delivered to the torch head can bemeasured once the predetermined plasma plenum pressure is established.In some cases, the off-valve pressure sensor 712 is used to determinethe pressure of gas directed to the flow-restriction element once thepredetermined plasma plenum pressure is established. Alternatively, insome embodiments, the vent off-valve 716 can be opened to vent theregion downstream of the flow restriction, such as downstream of a venthole of a nozzle to atmospheric pressure, and the first pressure can bedetermined (e.g., measured) upstream using a sensor (e.g., an off-valvepressure sensor 712).

A second pressure is also determined (906). In particular, the pressureof the gas that has passed through the flow-restriction element andexits the torch head can be measured. For example, as discussed above,in some cases, the vent off-valve can be closed so that a pressure(e.g., the second pressure) is generated within the vent region and theplasma plenum. In particular, the second pressure can be determined bymanually setting the second, downstream pressure (i.e., within thenon-vented plasma plenum) to a predetermined pressure (e.g., 4 psig),for example, by adjusting the pressure regulator 710. Alternatively, insome embodiments, the second pressure is determined by setting thedownstream pressure (e.g., the pressure within the vent region) toanother known pressure (e.g., atmospheric pressure), for example, byopening the vent off-valve 716 to open the vent passage to theatmosphere.

With the first and second pressures determined, a flow rate of the gasflow passing through the flow-restriction element can be determined(908). For example, in some embodiments, a flow rate of gas provided tothe torch can be measured, for example, using the flow detector 708.Alternatively or additionally, a flow rate of gas exiting the torch headthrough the vent (i.e., the gas stream G2) can be measured, for example,using the vent flow detector 718.

Then, using the detected first pressure, second pressure, and flow rate,the consumable can be identified (910). For example, once the gaspressures upstream and downstream of the flow-restriction element aredetermined and the flow rate of gas exiting the torch through the ventoff-valve (i.e., the gas stream G2) is determined, the consumable can beidentified (estimated) by accessing a look-up table. In some cases, alook-up table can include a listing of multiple torch consumables thatare defined by their respective expected flow characteristics that wouldbe produced using the identification methods described herein. In somecases, the look-up table can be electronically stored in a memory deviceof the torch control unit and accessed by the processor to identify theconsumable (e.g., automatically identify). Briefly referring to FIG. 12,in some embodiments, a lookup table 1300 can include expected values forplasma gas flow rates (e.g., as measured by the flow detector 708),plasma gas pressure (e.g., as measured by the off-valve pressure sensor712), vent gas flow rates (e.g., as measured by the vent flow detector718), and plasma plenum pressure (e.g., as measured by the plenumpressure sensor 714). Example values are provided for a variety ofdifferent consumables (e.g., nozzles), which can be described accordingto a cutting process in which they are used (e.g., 400 amp (A) mildsteel (MS), 260 A MS, 200 A MS, 130 A MS, 80 A MS, 50 A MS, and 30 A MSin the example chart listed). Using the lookup table 1300 and theexample pressure and flow detection methods described herein, the typeof consumable installed in the torch can be determined (estimated).

In some embodiments, the methods described herein can also include usinga flow coefficient equation, which is used to describe the relationshipbetween the pressure drop across an orifice and the corresponding flowrate through the orifice, to determine a dimension (e.g., acharacteristic dimension, such as average width (e.g., averagediameter)) of the orifice based the first pressure, the second pressureand the flow rate. For example, by knowing the pressure of fluidentering the orifice (e.g., the first pressure), the pressure of thefluid exiting the orifice (e.g., the second pressure), and the flow rateof fluid passing through the orifice, the flow coefficient can becalculated using commonly used flow coefficient equations. For example,alternatively or in addition to using the determined first pressure,second pressure, and flow rate to reference a look-up table to identifya consumable, in some embodiments, a control unit (e.g., a processor)can use the flow coefficient equations to determine what type ofconsumable is installed in the torch, for example, based on calculatingand comparing the estimated flow-restriction element (e.g., orifice)dimension to known or expected flow-restriction element (e.g., orifice)sizes for different consumable types.

Referring to FIG. 10, other methods, such as example method (1000) canalso be implemented to identify a consumable of a thermal processingtorch having a plasma chamber defined by an electrode and a nozzle. Asdescribed below, various methods can include adjusting gas flow throughthe consumable and monitoring the effect of the adjustments on flowcharacteristics observed upstream and/or downstream of the consumable.

For example, first, an inlet flow of a gas can be directed through a gassupply line to the plasma chamber (1002). For example, gas can bedelivered to a gas delivery system (e.g., the system 700) from a gassupply (e.g., the gas supply 702) through a gas supply line (e.g., alead line) to a plasma torch.

With gas being delivered, at least one of several gas flowcharacteristics can be manipulated (e.g., adjusted) (1004). For example,in some embodiments, the inlet flow of the gas to the plasma chamber canbe manipulated using a pressure regulator (e.g., the regulator 710)coupled to the gas supply line until a criterion, such as a thresholdpressure including a threshold plasma pressure is reached (1006). Thatis, if a vent valve (e.g., the vent valve 716) is already closed (basedon use of the torch), the regulator can be adjusted until the criterion(e.g., threshold plasma pressure value) is established. The thresholdplasma pressure value can be chosen based on the capabilities of the gasdelivery system. For example, in some cases, the threshold pressurevalue is about 4.0 pound per square inch (psig).

Alternatively or additionally, a vent valve (e.g., the vent off-valve716) coupled to a vent line connected to the plasma chamber can bemanipulated to control an outlet flow of the gas from the plasma chamber(1008). That is, in some embodiments, a previously open vent valve canbe manipulated (e.g., closed) to control the outlet flow of the gas fromthe plasma chamber to limit or prevent the outlet flow of the gas fromthe plasma chamber via the vent system prior to the criterion beingreached. For example, the vent valve can be closed to limit the outletflow of the gas from the plasma chamber (e.g., substantially eliminatingthe gas stream G2) so that the plasma plenum pressure can build to thethreshold plasma plenum pressure value. Alternatively or additionally,in some embodiments, the vent valve can be opened to vent the ventregion downstream of the flow restriction to establish the downstreampressure to be atmospheric pressure.

Next, a first value of an operating parameter of the torch associatedwith one of the inlet flow or the outlet flow of the gas can bedetermined (1010). The operating parameter can include any of variousgas flow properties, such as a pressure or flow rate into or out of theconsumable. For example, in some embodiments, the at least one operatingparameter can include a supply pressure of the inlet flow (e.g., asmeasured by the supply pressure sensor 706), a flow rate of the inletflow (e.g., as measured by the supply flow detector 708), an off-valvepressure of the inlet flow (e.g., as measured by the off-valve pressuresensor 712), or a flow rate of an outlet flow (e.g., the flow ratemeasured at the vent line (e.g., by the torch vent gas flow detector718) or the plasma gas flow rate). In some cases, the supply pressure ofthe inlet flow or the flow rate of the inlet flow can be measured (e.g.,measured using the supply pressure sensor 706) between a gas supplyvalve and the regulator (for example, when the regulator is positioneddownstream from the gas supply valve) coupled to the gas supply line. Insome embodiments, the off-valve pressure of the inlet flow is measuredby a pressure transducer, such as the off-valve pressure sensor 712positioned downstream from the regulator on the gas supply line.

Then, based on the first value of the operating parameter, theconsumable can be identified (1010). For example, a lookup table thatcorrelates one or more consumables with respective values of one or moreoperating parameters can be used to identify the consumable based on thefirst value of the operating parameter. For example, the lookup table1300 as discussed above can be used to identify a consumable installedin the torch.

In some cases, the method 1000 also includes manipulating (e.g.,opening) the vent valve to permit the outlet flow of the gas from theplasma chamber through the vent line after the criterion is reached(e.g., to produce the gas stream G2) and determining a second value ofthe operating parameter. Then, the first value and the second value ofthe observed operating parameter can be used to identify the consumable.For example, in some embodiments, the vent valve can be first closed sothat substantially only the gas stream G1 exits the torch and pressurecan build within the plasma plenum to the threshold pressure value(e.g., 4 psig) by adjusting a supply pressure regulator (e.g., regulator710). With the criterion reached (i.e., the threshold pressure valuereached within the vent passage line and the plasma plenum) and thefirst value of the plasma gas flow or the off-valve pressure (e.g., asmeasured by the pressure sensor 712) determined, the vent valve can bemanipulated (e.g., partially or fully opened) so that the downstreamvent region becomes exposed to atmospheric pressure and thereby producesthe gas stream G2.

With the vent valve opened, a second value of the operating parametercan be measured. That is, when the vent valve is opened and both the gasstreams G1 and G2 are being expelled from the torch, the variousoperating parameters (e.g., the supply pressure of the inlet flow, theflow rate of the inlet flow, the off-valve pressure of the inlet flow,or the flow rate of an outlet flow (e.g., G1 and/or G2)) are expected tochange as a result of the additional gas flows. Therefore, the secondvalue of the operating parameter and/or the difference or other changebetween the first and second values can be used to identify theconsumable disposed within the torch, for example, using a lookup table.

In some cases, the consumable can be a nozzle having at least onemetering hole of a unique dimension for a given nozzle design. That is,different nozzle designs (e.g., nozzles designed for different materialtypes or current values) can include differently sized metering holes,which can be determined using these methods. For example, a particularproduct line of nozzle, for example an entire line of gouging nozzles,piercing nozzles, or fine cut nozzles can all include the sameconfiguration (e.g., the same size) metering holes.

Additionally, in some aspects, another example method (1100) can beimplemented for identifying a consumable, such as a nozzle or a swirlring, of a thermal processing torch having a plasma chamber defined byan electrode and a nozzle.

First, an inlet flow of a gas can be directed through a gas supply valve(e.g., the supply off-valve 704) and a gas supply line to the plasmachamber of the torch (1102). For example, in some embodiments, the gassupply line can include a regulator (e.g., the regulator 710) and aplasma off-valve (e.g., the off-valve 704) coupled thereto to delivergas to the torch.

Next, the inlet flow of the gas can be adjusted until a thresholdpressure associated with the plasma chamber is reached (1104). Forexample, the regulator can be adjusted to change the pressure within theplasma chamber. In some embodiments, the threshold pressure is apressure of about 4.0 pound per square inch (psig) in the plasmachamber. As discussed above, a vent valve (e.g., the vent off valve 716)coupled to a vent line connected to the plasma chamber can bemanipulated (e.g., adjusted) to limit or prevent an outlet flow of thegas from the plasma chamber before the threshold pressure value isreached (1106). For example, in some cases, the vent valve can be closed(eliminating the gas stream G2) so that pressure can build within theplasma plenum and the threshold can be reached.

Once the threshold pressure is reached, a flow characteristic can bedetermined (1108). For example, in some embodiments, at least one of:(i) a first value of a pressure of the inlet flow (e.g., as measured bythe pressure sensor 706) (1110); (ii) a first value of a flow rate ofthe inlet flow (e.g., as measured by flow detector 708) (1112); (iii) afirst value of an off-valve pressure of the inlet flow (e.g., asmeasured by the off-valve pressure sensor 712) (1114); or (iv) a firstvalue of a flow rate of the outlet flow (e.g., as measured by the ventflow detector 718) (1116) can be determined.

After the first value of the flow characteristic is determined, the ventvalve can be adjusted (e.g., manipulated) to permit the outlet flow ofthe gas from the plasma chamber (1118). For example, in someembodiments, after the threshold value has been reached and the flowcharacteristic has been measured, the vent valve can be opened (e.g.,partially or fully opened) to permit an outlet flow of gas from theplasma chamber (e.g., through the flow restriction element anddownstream of the flow restriction element out of the vent passage).That is, opening the vent valve can cause the torch to begin expellingthe gas stream G2 from the torch. In some cases, adjusting (e.g.,manipulating) the vent valve to permit the outlet flow of the gas fromthe plasma chamber is performed prior to ignition of the torch.

The opening of the vent valve is expected to alter the flowcharacteristics of the torch system based on some of the gas enteringthe torch being expelled as the gas stream G2. Therefore, with theoutlet flow of gas from the plasma chamber, at least one of various flowcharacteristics can be determined (e.g., re-measured) (1120). Forexample, at least one of: (i) a second value of the pressure of theinlet flow (1122), (ii) a second value of the flow rate of the inletflow (1124), (iii) a second value of the off-value pressure of the inletflow (1126), or (iv) a second value of the flow rate of the outlet flow(1128) can be determined

Then, using the first and/or second values of the measured flowcharacteristics, the consumable can be identified (1130). For example,the measured flow characteristics can be referenced to a lookup table(e.g., the lookup table 1300).

Additionally, one or more of the steps or features of the variousmethods described herein can be implemented in a variety of combinationswith one another for identifying torch consumables.

While many of the systems and methods herein (e.g., the method 900, themethod 1000, and the method 1100) have generally been described andillustrated as being used and implemented primarily in association withplasma arc torches, they can also be implemented with other materialprocessing systems, such as water jet systems. For example, during use,fluids, such as gases or liquids (e.g., water) can be directed to one ormore components of a water jet cutting system, such as a water jetorifice, a mixing tube used to mix abrasive particles with fluid, and/orone or more high pressure cylinders or pump components to generate thehigh velocity water flow used to cut material. As with the plasma arctorches discussed above, the fluids can be directed through one or moreof these components in accordance with the methods described herein toidentify the consumables installed in the water jet system. For example,fluid pressure and/or flow rate can be monitored upstream and downstreamof the water jet orifice to identify the type of orifice installed inthe system.

It should also be understood that various aspects and embodiments of theinvention can be combined in various ways. Based on the teachings ofthis specification, a person of ordinary skill in the art can readilydetermine how to combine these various embodiments. In addition,modifications may occur to those skilled in the art upon reading thespecification. The present application includes such modifications andis limited only by the scope of the claims.

What is claimed is:
 1. A method for identifying a consumable of athermal processing torch comprising: directing a gas flow through aflow-restriction element associated with the consumable disposed withinthe thermal processing torch; determining a first pressure of the gasflow at a location upstream relative to the flow-restriction element;determining a second pressure of the gas flow at a location downstreamfrom the flow-restriction element; determining a flow rate of the gasflow passing through the flow-restriction element; and using the firstpressure, the second pressure, and the flow rate to identify theconsumable.
 2. The method of claim 1, wherein: determining the firstpressure comprises setting the gas flow to a known pressure; anddetermining the flow rate comprises measuring the flow rate.
 3. Themethod of claim 1, wherein: determining the flow rate comprises settingthe gas flow rate to a known value; and determining the first pressurecomprises measuring the pressure of the gas flow.
 4. The method of claim1, where determining a second pressure of the gas flow comprisesestablishing the pressure as atmospheric.
 5. The method of claim 1,wherein the flow-restriction element is an orifice associated with theconsumable.
 6. The method of claim 5, further comprising using a flowcoefficient equation to determine a dimension of the orifice based thefirst pressure, the second pressure and the flow rate.
 7. The method ofclaim 6, wherein the dimension of the orifice is correlated to theconsumable or a type of the consumable for identifying the consumable.8. The method of claim 1, wherein the flow-restriction element comprisesan exit orifice of a nozzle.
 9. The method of claim 1, wherein theflow-restriction element comprises a vent hole.
 10. The method of claim9, wherein different flow-restriction elements are selected fordifferent types of consumables.
 11. The method of claim 1, wherein theflow-restriction element comprises absence of a vent hole.
 12. A methodfor identifying a consumable of a thermal processing torch, the torchincluding a plasma chamber defined by an electrode and a nozzle, themethod comprising: directing an inlet flow of a gas through a gas supplyline to the plasma chamber; manipulating at least one of: a) the inletflow of the gas to the plasma chamber using a regulator coupled to thegas supply line until a criterion is reached; or b) a vent valve coupledto a vent line connected to the plasma chamber to control an outlet flowof the gas from the plasma chamber; determining a first value of atleast one operating parameter of the torch associated with one of theinlet flow or the outlet flow of the gas; and identifying the consumablebased on the first value of the at least one operating parameter. 13.The method of claim 12, wherein manipulating the vent valve to controlthe outlet flow of the gas from the plasma chamber comprises limitingthe outlet flow of the gas from the plasma chamber prior to thecriterion being reached.
 14. The method of claim 13, further comprising:manipulating the vent valve to permit the outlet flow of the gas fromthe plasma chamber through the vent line after the criterion is reached;determining a second value of the at least one operating parameter ofthe torch; and using the first value and the second value of the atleast one operating parameter to identify the consumable.
 15. The methodof claim 12, wherein the at least one operating parameter comprises oneof a supply pressure of the inlet flow, a flow rate of the inlet flow,an off-valve pressure of the inlet flow, or a flow rate of the outletflow.
 16. The method of claim 15, wherein the supply pressure of theinlet flow or the flow rate of the inlet flow is measured between a gassupply valve and the regulator coupled to the gas supply line, theregulator being positioned downstream from the gas supply valve.
 17. Themethod of claim 15, wherein the off-valve pressure of the inlet flow ismeasured by a pressure transducer positioned downstream from theregulator on the gas supply line.
 18. The method of claim 15, whereinthe flow rate of the outlet flow is measured at the vent line.
 19. Themethod of claim 12, further comprising using a lookup table to identifythe consumable based on the first value, wherein the lookup tablecorrelates one or more consumables with respective values of one or moreoperating parameters.
 20. The method of claim 12, wherein the criterioncomprises a threshold pressure value of about 4.0 pound per square inch(psig) in the plasma chamber.
 21. The method of claim 12, wherein theconsumable is a nozzle comprising at least one metering hole of a uniquedimension for a given nozzle design.
 22. A method for identifying aconsumable of a thermal processing torch, the torch including a plasmachamber defined by an electrode and a nozzle, the method comprising:directing an inlet flow of a gas through a gas supply valve and a gassupply line to the plasma chamber, wherein the gas supply line has aregulator and a plasma off-valve coupled thereto; adjusting the inletflow of the gas until a threshold pressure associated with the plasmachamber is reached; manipulating a vent valve coupled to a vent lineconnected to the plasma chamber to limit an outlet flow of the gas fromthe plasma chamber before the threshold pressure value is reached;determining at least one of: (i) a first value of a pressure of theinlet flow, (ii) a first value of a flow rate of the inlet flow, (iii) afirst value of an off-valve pressure of the inlet flow, or (iv) a firstvalue of a flow rate of the outlet flow; manipulating the vent valve topermit the outlet flow of the gas from the plasma chamber after thethreshold value is reached; determining at least one of: (i) a secondvalue of the pressure of the inlet flow, (ii) a second value of the flowrate of the inlet flow, (iii) a second value of the off-value pressureof the inlet flow, or (iv) a second value of the flow rate of the outletflow; and using the first or second value of the pressure of the inletflow, the first or second value of the flow rate of the inlet flow, thefirst or second value of the off-valve pressure of the inlet flow, orthe first or second value of the flow rate of the outlet flow, or acombination of any two or more such values, to identify the consumable.23. The method of claim 22, wherein the threshold pressure comprises apressure of about 4.0 pound per square inch (psig) in the plasmachamber.
 24. The method of claim 22, wherein the consumable is a nozzlecomprising at least one metering hole of a unique dimension.
 25. Themethod of claim 22, further comprising using a flow sensor coupled tothe gas supply line to measure the flow rate of the inlet flow, the flowsensor being positioned between the gas supply valve and the regulator.26. The method of claim 22, further comprising using a flow sensorcoupled to the vent line to measure the flow rate of the outlet flow,the flow sensor being positioned downstream from the vent valve.
 27. Themethod of claim 22, wherein the first and second values of the pressureof the inlet flow is measured upstream from the regulator.
 28. Themethod of claim 22, wherein the first and second values of the flow rateof the inlet flow is measured upstream from the regulator.
 29. Themethod of claim 22, wherein the first and second values of the off-valvepressure of the inlet flow is measured downstream from the regulator.30. The method of claim 22, wherein the first and second values of theflow rate of the outlet flow is measured at the vent line.
 31. Themethod of claim 22, wherein manipulating the vent valve to permit theoutlet flow of the gas from the plasma chamber is performed prior toignition of the torch.
 32. A system for identifying a consumable of athermal processing torch, the system comprising: a flow-restrictionelement associated with the consumable and configured to receive a gasflow therethrough; a first sensor to determine a first pressure of thegas flow through the flow-restriction element at a location upstreamrelative to the flow-restriction element; a second pressure determiningdevice to establish a second pressure of the gas flow through theflow-restriction element at a location downstream from theflow-restriction element; a flow meter for measuring a flow rate of thegas flow passing through the flow-restriction element; and a processorthat uses the first pressure, the second pressure, and the flow rate toidentify an operating characteristic of the consumable.
 33. The systemof claim 32, further comprising at least one radio-frequencyidentification (RFID) tag on, in, or, in communication with theconsumable for identifying the consumable.
 34. The system of claim 32,wherein the second pressure determining device comprises a deviceconfigured set the second pressure to atmospheric pressure.
 35. Thesystem of claim 34, wherein the device configured set the secondpressure to atmospheric pressure comprises a vent valve.
 36. The systemof claim 32, wherein the second pressure determining device comprises asecond pressure sensor.
 37. A torch of a cutting system configured toidentify a consumable installed in the torch, the torch comprising: avent passage fluidly connected to a fluid flow path of the torch; a flowdetection device configured to detect a rate of fluid flow beingexpelled from the torch through the vent passage; and a vent valvefluidly connected to the vent passage configured to limit the fluid flowfrom being expelled from the fluid flow path of the torch through thevent passage.
 38. The torch of claim 37, further comprising a pressuresensor fluidly connected to the vent passage, the pressure sensor beingconfigured to detect a fluid pressure within the vent passage.
 39. Thetorch of claim 37, wherein the fluid flow path comprises a plasma plenumregion of the torch.
 40. The torch of claim 39, wherein the vent passageis fluidly connected to the fluid flow path by an identifying orifice ofthe consumable installed in the torch.